INDIAN RAILWAY AIR BRAKE

SYSTEM
By
Syed Khaja Hussain B.Tech., M.B.A.
Instructor/Running

DTTC/GTL/SCR

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 Brake System
Types of Brake System

28 LV1 KNORR 28LAV1 IRAB CCB

Loco Formation Loco Formation Loco Formation Loco Formation

Brake Brake Brake Brake Brake Brake Brake Brake

AIR Vacuum AIR Vacuum AIR Both AIR AIR

Air &
Vacuum
(Dual)

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 Brake System
Types of Brake System in Locomotives

28 LV1 KNORR 28LAV1 IRAB CCB

WDM2A WDG4
YDM4 WDS4B
NON MODIFIED
MODIFIED WDP4
WDS6 ZDM3 WDP1
WDG3A
28 VB C3W
PROPOTIONAL DISTRIBUTER WDM3A
VALVE VALVE
WDM3D
SA9 FOOT
QUICK REALASE PEDAL
Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
 VALVES USED & THEIR FUNCTION
SL DESCRIPTION PURPOSE
1 A9. Automatic Valve Brake application for Loco as well as formations

2 SA 9 Ind. Brake Valve Brake Application for Loco alone

3 MU – 2B M.U. Operation.
4 F 1 – Selector M. U. Operation
5 Addl C 2Valve Feeding B. P. Pressure to formation
6 24 A. Double Check This will allow only one Valve operation at a time.

7 C3W. Distributor Valve Proportionate Brake application during A9 application.

8 C2. Relay Valve For Locomotive Brake

9 Pressure Switch Loco will be brought to idle during A9 emergency

application

10 D1. Emergency Valve For Emergency brake application

Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
 VALVES USED & THEIR FUNCTION

SL DESCRIPTION PURPOSE
11 D1. Pilot air valve To release Loco brake

12 Pressure Limiting Valve Pilot air to C 2.Relay is Limiting to 1.8 kg / Cm 2

13 M. R. Safety Valve When M. R. Pressure goes beyond 10.5 kg This

(Main Reservoir) Valve will function

14 Duplex Check Valve Set It will not allow MR equalising pipe Air to return back
at 5 kg / Cm2 to MR

15 F2/C2N Feed Valve To maintain Feed pipe Pr at 6 kg / Cm2

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
SA-9 Ind brake valve C2 RELAY VALVE
A9-Automatic Brake Valve

F-1 Selector Valve 24 A. Double Check

MU-2B valve
Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
C2 RELAY VALVE D-1 Emergency Brake Valve-

LOCO BRAKE CYLINDER

C3W DISTRIBUTOR VALVE

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 BP (GREEN) PIPE
FP (WHITE) PIPE

AIR FLOW INDICATOR

WHITE NEEDLE (REFERENCE)
RED NEEDLE (REGESTER)

AIR FLOW MEASURING VALVE

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
SA9 CUT OUTCOCK IN CONTROL STAND
A9 CUT OUT COCK IN CONTROL STAND
PRESSURE SWITCH

MR SAFETY VALVE Syed Khaja Hussain F2 FEED VALVE

Instructor/Rng/DTTC/GTL
 SA-9 (Working SA-9 Release
Control Stand) Loco Brake Application By SA-9 (Non-Working Control Stand)

MR2 30 20
20 30

SA9 COC BRAKE SYSTEM 8 to 10 KG/CM2 SA9

COC(MR-2 COC) COC

DCV
3.5 KG/CM2 TRAIL
MU2B
2 3.5 KG/CM2
LEAD
20
From C3W
DCV DV

C-2 RELAY BC Gauge

VALVE

1 2
MR-2

3
APPLY-SA9
3.5 KG/CM2

Bogie Isolation COC-2 Bogie Isolation COC-1

Brake Cylinder Brake Cylinder
Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL
 SA-9 (Working
Control Stand) SA-9 (Non-Working
Control Stand)

MR2 30 20
20 30
Exh -Port BRAKE SYSTEM SA9
SA9 COC (MR-2 COC) COC
COC

DCV
0 KG/CM2 TRAIL
MU2B 0 KG/CM2
2 LEAD

From C3W
20 DCV
DV

BC Gauge
C-2

2
MR-2 1

3
0 KG/CM2
Exhaust Port

Brake Cylinder Bogie Isolation COC-2 Bogie Isolation COC-1 Brake Cylinder
Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL
 A-9 Release (Non-
A-9 (Working
Control Stand)
Ex Brake Pipe Charging in IRAB Working Control Stand) Ex
1 1

MR2 30 5
5 30
BRAKE SYSTEM A9 COC
A9 COC
COC(MR-2 COC)
8 to 10 KG/CM2
Open Close

5 KG/CM2 Closes below 4.5 Kg/cm2 TRAIL

Opens above 4.8 Kg/cm2 VCD COC
OPEN 5 KG/CM2
3
P1 13
Airflow LEAD Exhaut Port

Indicator VCD
Magnet
MU2B Valve
R6 Addl. C-2 BP Gauge
RELAY VALVE
2
MR2 Drops out 2.8 Kg/cm2
Choke 5.5 MM
1 Picks up at 4.0 Kg/cm2
3 P2 PCS
Air Flow
Run/Rel. 5 KG/CM2
Magnet
Measuring Valve
3/4 “ OR Closes below 4.4 Kg/cm2
EX Opens above 4.7 Kg/cm2 PCS
Valve
1” BP COC COC
19.5 MM Open
Open

BP PIPE LINE Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

When SP1/SP2 Pressed --- Quick Charging of BP Pressure takes place

 A-9 (Non-Working
Exhaust Port GRADUATED APPLICATION in IRAB Control Stand) Ex

1 1
A-9 (Working
MR2 30 5
5 30 Control Stand)
BRAKE SYSTEM 8 to 10 KG/CM2 A9 COC
A9 COC COC(MR-2 COC)
Close
Open

Closes below 4.5 Kg/cm2 MU2B

Airflow Opens above 4.8 Kg/cm2 TRAIL VCD COC
Indicator OPEN 5 KG/CM2
3 EX
P1 13 LEAD VCD
Magnet
Valve

R6 BP
Addl. C-2
RELAY VALVE Gauge
2
MR2
Choke 5.5 MM Drops out 2.8 Kg/cm2
1 Picks up at 4.0 Kg/cm2
3
Run/Rel. P2
Airflow Magnet
PCS
Measuring Valve Closes below 4.4 Kg/cm2
3/4 “ OR
Valve EX Opens above 4.7 Kg/cm2 PCS
1” BP COC COC
19.5 MM Open
Open

BP PIPE LINE
Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL
 MR -2 BP Destroy
BP Pipe Line Connection Foot Pedal Not Pressed
MR-2
C-3 W BKIV
MR-2
DV
Limiting Valve

Isolation BC 4 16
Handle 1.8 Kg/CM2 EXH F-1 Selector
MR-2
Isolation
Cock DCV
QRV From C3W DV
Open From SA-9
C-2

2
MR-2 1 1.8 KG/CM2
3
1.8 KG/CM2

Bogie Isolation Coc-2 Bogie Isolation Coc-1

Brake Cylinder

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

Prop by BP drop
 MR -2 BP 5 Kg / cm2 BKIV Foot Pedal Not Pressed
MR-2
C-3W
BP Pipe Line Connection
DV
BC 1.8 Kg/Cm2 4 16
MR-2
Isolating EXH Port Limiting
handle Valve MR-2 EXH F-1 Selector
Isolation
Cock QRV DCV
Open From SA-9
C2 Relay Valve

2
MR-2
MR- 1 0 KG/CM2
0 KG/CM2
3
EXH Port

Bogie Isolation Coc-2 Bogie IsolationCoc-1

Brake Cylinder Brake Cylinder

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

Prop. release by BP
 MR -2 BKIV When Foot Pedal Pressed
BP Pipe Line Connection MR-2
C-3W
MR-2
DV
Limiting
BC Valve
Isolating EXH
handle F-1 Selector
Isolation MR-2
Cock Releaser DCV
Open From SA-9
C-2 Relay Valve

2
MR-2
MR 1
0 KG/CM2 0 KG/CM2
3
EXH Port

Bogie Isolation Coc-2 Bogie Isolation Coc-1

Brake Cylinder Brake Cylinder

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

By PVEF
 MR -2 BKIV Foot Pedal Not Pressed
MR-2
C-3W BP Pipe Line Connection
DV
BC 1.8 Kg/Cm2 4 16
MR-2
Isolating EXH Port Limiting
handle Valve MR-2 EXH F-1 Selector
Isolation
Cock DCV
Open QRV From SA-9
C2 Relay Valve

2
MR-2
MR- 1 0 KG/CM2
0 KG/CM2
3
EXH Port

Bogie Isolation Coc-2 Bogie IsolationCoc-1

Brake Cylinder Brake Cylinder

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

Prop. release by BP
 MR2 When MR EQ Pipe & BC EQ Pipe are coupled

MU2B (Lead) From C3W DV MU2B(Trail)

SA-9 2 From C3W DV SA-9
20 DCV DCV
X

C-2
C-2 2
2
MR2 MR2
1 1
EXH EXH
BC EQ 3
3
F-1 (Lead) F-1 (Trail)
DTTC DTTC
w
GTL w
GTL

MREQ

MR2 MR1 MR1 MR2

Syed Khaja Hussain
To Brake To Brake
System LEADING LOCO Instructor/Rng/DTTC/GTL TRAILING LOCO System
 MR2 When MR EQ Pipe & BC EQ Pipe are coupled
MU2B (Lead) B P MU2B(Trail)

SA-9 2 MR2 MR2 SA-9

From C3W DV From C3W DV
DCV DCV
20
X

C-2
C-2 2
2
MR2 1 MR2
1
EXH EXH
BC EQ 3
3
F-1 (Lead) F-1 (Trail)
DTTC DTTC
w
GTL w
GTL

MREQ

MR2 MR1 MR1 MR2

Syed Khaja Hussain
To Brake To Brake
System LEADING LOCO Instructor/Rng/DTTC/GTL TRAILING LOCO System
 When MR EQ & BC EQ Pipes are not coupled only B.P connected

BP ( Live loco) BP ( Dead Loco )

Isolation COC
F1 (Auto Lead) BKIV LV MR Gauge
From SA9 DCV 16 4
1.8 Kg/CM2
C3W DV

5 Kg/CM2

MU2B (Lead)

5 Kg/CM2
MR-2
2
C2 Relay 1 MR2
Valve
EXH NRV
3

MR-1
BC

6. 1.
5.
So,
7.
4.The
When
And
pilot
As BP
2.
3.MR2
air
suchBP
Further
pressure
Then
pressure
pressure
pressure
MR from
this
of from
pressureMR2
Live
reduces
pressure
waiting
( loco
5Air
MR2 ,Pressure
at
is
goes
C3W
Kg/Cm2) goes
charged
portto
D.V.
to
No.
isMR-2through
goes
port
ofto
1 dead
enters
to
dead
no.
available port
2loco
atloco,
of
inC-2
No.1
C3W
brake
C-2
get
therelay
of
unbalanced
distributor
Relay cylinder
same
C2Valve
valve
relay
BPofto
(1.8
pressure
valve.
valve
and
apply
Kg
deadconnect
/Loco
Cm2)
goes as
loco.
Syed Khaja Hussain
per the setting
MR2 pressure
of Limiting
to brakes
C3W
viaValve.
DV
C3W
in Through
dead
to
Where
F1
loco.
Selector
Isolation
it(operates
Maxport1.8Kg/Cm2)
Instructor/Rng/DTTC/GTL
COC C-2
no.
ofrelay
4dead
to 16
valve
loco
to Dfor
C application.
V
Dead
 FEED PIPE CHARGING
MR Safety valve

J Filter
Main Reservoir
Main Reservoir 11

Control reservoir, auxiliaries etc.

Brake system COC

Main Reservoir 2

Check valve Duplex check valve

5 Kg/cm2
To MR Equalizing pipe
J Filter
To Brake system Feed valve
D24B
6 Kg/cm2
Feed Valve COC

FEED PIPE ( 6 Kg/cm2)

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL
 WORKING PRINCIPLE
OF TWIN PIPE AIR BRAKE
SYSTEM

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

 PARTS OF TWIN PIPE SYSTEM
Feed Pipe

BrakePipe

Isolation COC FP Isolation COC BP

Control Res.
Dust Collector FP Dust Collector BP

Distributor Valve
NRV
Aux. Res.
EX
Brake Cylinder QRV Brake Cylinder

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

 CHARGING FP

BP

BC BP
is ConnectedTo
& CR Exhaust
Charged to BC22in
5kg/cm
IC FP &Released
AR Charged to 6kg/cm
Condition IC

CR
DC
DC

NRV DV
Aux.Res.
6 kg/cm2
EX
QRV BC
BC

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

 RECHARGE
APPLICATION
FP

BP

BP
BC isCRReduced
AR connected
is Connected ToinBC
is connected
to Steps
exaustBCto
to&BP &
BC Apply
AR Brake &
is disconnected
pressure
Pressure comes
Reaches CR
tois 2
3.8kg/cm
IC BP Recharged
zero &&Brakes to
Disconnected
From BC 5kg/cm
areApplied
Brakes are released
2
IC

CR
DC
DC

NRV DV
AR
EX
QRV BC
BC

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

 MANUAL RELEASE
FP

BP

BCisconnected
Qrv topressureComes
pulled & CR exaust BC pressure
to zero
IC IC
comes to zero & brakes are released
CR
DC DC

NRV DV
AR
EX
QRV
BC BC

Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL

Thank You

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL